Method of producing a component by welding

ABSTRACT

An embodiment provides a method of producing a component. A rigidity-reinforcing part is formed on a first part, a second part, or a third part adjacent to a point where a preceding weld and a following weld intersect each other. The first part and the second part are coupled to each other by performing the preceding weld in a state of overlapping and a part of a first junction part and a second junction part are pressurized. After performing the preceding weld, the first part, the second part, and the third part are coupled to each other by pressurizing and performing a following weld while overlapping a part of a third junction part with an opposite part of the first junction part and overlapping a remaining part of the third junction part with a cross junction part.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a division of U.S. application Ser. No. 16/931,647,filed on Jul. 17, 2020, which claims priority to Korean PatentApplication No. 10-2019-0171618, filed on Dec. 20, 2019, whichapplications are hereby incorporated herein by reference.

TECHNICAL FIELD

The present invention relates to a component produced by welding and amethod of producing the same.

BACKGROUND

When welding panels of steel or aluminum, or panels made of differentmaterials from each other, laser brazing welding may be used dependingon welding quality assurance and exterior design needs.

However, in a case of laser brazing welding, since a thin panel is to beused, it is difficult to secure rigidity of the panel material itself.Also, there is a possibility of deformation by external force clampingthe thin panel for welding. Since the two panels are pressurized againsteach other, spring back may occur after welding. In particular, whenwelding lines of three or more panels are welded by being intersectedwith each other, two or more welding lines intersect each other. Due tothe overlapping of the welding at the intersection point, thermal stressbecomes excessive, and thus there is a problem in that the deformationoccurs at the welding position of the panel, and a pinhole is generatedwhen the thermal stress is severe.

In order to solve this problem, it is necessary to avoid welding partsbeing overlapped. However, in this case, there is a problem in thatrealization of a design for a desired product becomes difficult. Thus,there is a requirement for a technology capable of preventing weldingdefects while securing the design of a product as desired.

The foregoing is intended merely to aid in the understanding of thebackground of the present invention, and is not intended to mean thatthe present invention falls within the purview of the related art thatis already known to those skilled in the art.

SUMMARY

The present invention relates to a component produced by welding and amethod of producing the same. Particular embodiments relate topreventing a defect of a welding area from occurring when producing bywelding a plurality of panels having welding lines to be intersectedwith each other through laser brazing welding and the like.

Embodiments of the present invention provide a component produced bywelding, the component including a first part in which a first junctionpart is configured, a second part in which a second junction part and across junction part intersecting the second junction part areconfigured, the second junction part is coupled to the first part suchthat a part of the first junction part and the second junction part areoverlapped, and preceding weld is performed for the second junction partand the first junction part, and a third part in which a third junctionpart is configured, a part of the third junction part is overlapped withan opposite part of the first junction part, a remaining part of thethird junction part is overlapped with the cross junction part, and thefirst part and the second part are coupled to the third part byperforming following weld for each of the overlapped parts, wherein arigidity-reinforcing part is formed on the first part, the second part,or the third part adjacent to a point where the preceding weld and thefollowing weld intersect each other.

The preceding weld and the following weld may be laser welding.

The first junction part, the second junction part and the cross junctionpart, and the third junction part may be respectively configured on afirst flange, a second flange, and a third flange respectively formedalong edges of the first part, the second part, and the third part.

The first part, the second part, and the third part may be made of sameor different metals.

The second junction part and the cross junction part may be configuredby dividing a section along an edge of the second part, whereby thesecond junction part and the cross junction part may intersect eachother at a point where the second junction part and the cross junctionpart may meet each other.

The rigidity-reinforcing part may be in a groove shape recessed to acertain depth.

The rigidity-reinforcing part may be formed at a position between thesecond junction part and the cross junction part, the position beingwhere the second junction part and the cross junction part may meet eachother in the second part.

The rigidity-reinforcing part may be formed at a position inclinedtoward the second junction part between the second junction part and thecross junction part.

The rigidity-reinforcing part may be positioned to be inclined towardthe second junction part from a point between the second junction partand the cross junction part, and may be in a groove shape recessed to acertain depth so as to be connected to the second junction part.

In the second part, the second junction part and the cross junction partmay be spaced apart from each other at all points except points wherethe second junction part and the cross junction part may meet eachother, and a plurality of rigidity-reinforcing parts may be formed at acertain interval between the second junction part and the cross junctionpart spaced apart from each other.

A sealer may be filled in a recess of the rigidity-reinforcing part.

The sealer may be connected to a pinhole formed at the point where thepreceding weld and the following weld may intersect each other, and maybe filled in the pinhole.

The first part may be an upper panel of an outer panel assembly of atailgate of a vehicle, the third part may be a lower panel of the outerpanel assembly of the tailgate, and the second part may be an extensionpanel disposed between the upper and lower panels of the outer panelassembly of the tailgate.

In the first part and the third part, both side ends thereof may bewelded to each other, a central part therebetween may be spaced apartfrom each other, the second part may be disposed in the central part,and the preceding weld and the following weld may intersect each otherat an acute angle at a point where the first part, the second part, andthe third part may intersect each other.

A method of producing a component of embodiments of the presentinvention may include forming a rigidity-reinforcing part on a firstpart, a second part, or a third part adjacent to a point where apreceding weld and a following weld may intersect each other, couplingthe first part and the second part to each other by performing thepreceding weld in a state of overlapping and pressurizing a part of afirst junction part and a second junction part, and coupling the firstpart, the second part, and the third part to each other by pressurizingand performing the following weld while overlapping a part of a thirdjunction part with an opposite part of the first junction part andoverlapping a remaining part of the third junction part with a crossjunction part.

According to the component produced by welding and the method ofproducing the same of embodiments of the present invention, it ispossible to prevent a defect of a welding area from occurring whenproducing by welding a plurality of panels having welding linesintersecting each other through laser brazing welding and the like.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1 to 3 are views showing a first part, a second part, and a thirdpart of a component produced by welding according to an exemplaryembodiment of the present invention.

FIG. 4 is a view showing a state in which a first part and a second partof a component produced by welding according to an exemplary embodimentof the present invention are coupled to each other.

FIG. 5 is a cross-sectional view taken along line A-A of the componentshown in FIG. 4 .

FIG. 6 is a view showing a state in which all components produced bywelding according to an exemplary embodiment of the present inventionare coupled to each other.

FIG. 7 is a cross-sectional view taken along line B-B of the componentshown in FIG. 6 .

FIG. 8 is a cross-sectional view taken along line C-C of the componentshown in FIG. 6 .

FIG. 9 is a cross-sectional view taken along line D-D of the componentshown in FIG. 6 .

FIG. 10 is an enlarged view of a portion of the second part at line A-Ashown in FIG. 2 .

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

FIGS. 1 to 3 are views showing a first part, a second part, and a thirdpart of a component produced by welding according to an exemplaryembodiment of the present invention. FIG. 4 is a view showing a state inwhich a first part and a second part of a component produced by weldingaccording to an exemplary embodiment of the present invention arecoupled to each other. FIG. 5 is a cross-sectional view taken along lineA-A of the component shown in FIG. 4 . FIG. 6 is a view showing a statein which all components produced by welding according to an exemplaryembodiment of the present invention are coupled to each other. FIG. 7 isa cross-sectional view taken along line B-B of the component shown inFIG. 6 . FIG. 8 is a cross-sectional view taken along line C-C of thecomponent shown in FIG. 6 . FIG. 9 is a cross-sectional view taken alongline D-D of the component shown in FIG. 6 . FIG. 10 is an enlarged viewof a portion of the second part at line A-A shown in FIG. 2 .

Embodiments of the present invention relates to a component produced bywelding and a method of producing the same, which may prevent a defectof a welding area from occurring when producing by welding a pluralityof panels having welding lines intersecting each other through laserbrazing welding and the like.

FIGS. 1 to 3 are views showing the first part 100, the second part 300and the third part 500 of the component produced by welding according toan exemplary embodiment of the present invention. The component producedby welding includes the first part 100 in which a first junction part120 is configured, a second part 300 in which a second junction part 320and a cross junction part 340 intersecting the second junction part 320are configured, the first part 100 is coupled to the second part suchthat a part 122 of the first junction part and the second junction part320 are overlapped, and a preceding weld W1 is performed for the secondjunction part 320 and the first junction part 120, and a third part 500in which a third junction part 520 is configured, a part 524 of thethird junction part 520 is overlapped with an opposite part 124 of thefirst junction part, a remaining part 522 of the third junction part 520and the cross junction part 340 are overlapped, and the first part 100and the second part 300 are coupled to each other by which a followingweld W2 is performed for each of the overlapped parts, wherein arigidity-reinforcing part 360 is formed in the first part 100, thesecond part 300, or the third part 500 adjacent to a point where thepreceding weld W1 and the following weld W2 intersect each other.

Particularly, an embodiment of the present invention is a case wherethree parts are put together to form a singular component assembly, andfor example, the panels are joined together by welding.

An exemplary embodiment to which the present invention may be applied isan outer panel assembly forming an outer surface of a tailgate of avehicle, wherein the first part 100 is an upper panel of the outer panelassembly of the tailgate of the vehicle, the third part 500 is a lowerpanel of the outer panel assembly of the tailgate, and the second part300 may be an extension panel disposed between the upper panel and lowerpanels of the outer panel assembly of the tailgate. However, thetechnical idea of the present invention is not only applied to thetailgate, but is applicable to a door panel or various exterior panelsof a vehicle, and further, to various industrial components.

In embodiments of the present invention, since a thin panel is to beused, it is difficult to secure rigidity of the panel material itself,and thus there is a possibility of having deformation by external forceclamping the thin panel for welding. In addition, in embodiments of thepresent invention, the preceding weld W1 and the following weld W2 maybe laser welding. In detail, laser brazing welding may be correspondedto the case above. In this case, when the welding lines intersect eachother at WC, thermal stress becomes excessive so that deformation occursand a pinhole may be generated due to an excessive spring backphenomenon. Therefore, in order to solve this problem, embodiments ofthe present invention propose a structure for preventing the deformationand welding defects by providing more rigidity to a panel through changeof the panel shape.

Particularly, FIG. 1 shows the first part 100, and the first junctionpart 120 is configured at a lower end of the first part 100 as shown.FIG. 2 shows the second part 300, and the second junction part 320 isconfigured at the upper end of the second part 300, and the crossjunction part 340 intersecting the second junction part 320 isconfigured at the lower end thereof. As shown in FIG. 4 , the secondpart 300 is coupled to the first part 100 such that a part 122 of thefirst junction part and the second junction part 320 are overlapped witheach other. Then, the preceding weld W1 is performed for the secondjunction part 320 and the first junction part 120.

FIG. 3 shows the third part 500, and the third junction part 520 isconfigured in the third part 500. As shown in FIG. 6 , a part 524 of thethird junction part 520 and an opposite part 124 of the first junctionpart 120 are overlapped with each other, the remaining part 522 of thethird junction part 520 and the cross junction part 340 are overlappedwith each other, and the following weld W2 is performed for each of theoverlapped parts, whereby the first part 100 and the second part 300 arecoupled to the third part 500. Through this process, the first part 100,the second part 300, and the third part 500 are coupled to each other bywelding.

In this case, there is no problem when welding lines are not crossedwith each other. However, at the point WC where the preceding weld W1and the following weld W2 intersect each other, the deformation andthermal stress of the material due to clamping are excessive, so thatthe breakage of the material or a pinhole may occur due to the springback phenomenon. Accordingly, the rigidity-reinforcing part 360 isformed in the first part 100, the second part 300, or the third part 500adjacent to the point where the preceding weld W1 and the following weldW2 intersect each other.

The rigidity-reinforcing part 360 is provided for imparting rigidity toa material in order to prevent the spring back phenomenon after weldingof the material due to pressure applied during the welding, provided forpreventing poor quality caused by the spring back due to the thermalstress after the welding, and also provided for overcoming a problemsuch as having a step difference generated by the spring back whenperforming the following weld W2. In particular, in the case when thepinhole is generated, the rigidity-reinforcing part 360 may be utilizedto fill the pinhole with a sealer and the like, so that a paintedsurface may be kept smooth when subsequent painting is performed.

Particularly, the first junction part 120, the second junction part 320and the cross junction part 340, and the third junction part 520 may berespectively configured at the first flange, the second flange, and thethird flange respectively formed along the edges of the first part 100,the second part 300, and the third part 500. The first flange, thesecond flange, and the third flange are formed into a surface shapehaving a predetermined area by bending the edge part of the panel. Also,the first flange, the second flange, and the third flange are to playthe roles of the first junction part 120, the second junction part 320and the cross junction part 340, and the third junction part 520,respectively.

In addition, the first part 100, the second part 300, and the third part500 may be made of the same or different metal materials. Particularly,in the case of aluminum, the bonding is performed through laser weldingor the like. Aluminum has a good flexible rate, but is also susceptibleto breakage, and thus effective results may be obtained when embodimentsof the present invention are applied.

Meanwhile, the second junction part 320 and the cross junction part 340are configured by dividing a section along the edge of the second part300 as shown in FIG. 2 , whereby the second junction part 320 and thecross junction part 340 may intersect each other at a point where thesecond junction part 320 and the cross junction part 340 meet eachother. The illustrated exemplary embodiment is a case where the secondjunction part 320 and the cross junction part 340 configure points bymeeting each other at both ends of the second part 300.

In addition, the rigidity-reinforcing part 360 may be in a groove shaperecessed to a certain depth as shown in FIG. 10 . Therigidity-reinforcing part 360 may be formed at a point between thesecond junction part 320 and the cross junction part 340, which is apoint where the second junction part 320 and the cross junction part 340meet each other in the second part 300. In particular, as shown in thedrawings, the rigidity-reinforcing part 360 may be formed at a pointinclined toward the second junction part 320 from a point between thesecond junction part 320 and the cross junction part 340.

Particularly, the rigidity-reinforcing part 360 is positioned to beinclined toward the second junction part 320 from a point between thesecond junction part 320 and the cross junction part 340, and may be ina groove shape recessed to a certain depth so as to be connected to thesecond junction part 320. In addition, the sealer may be filled in therecess of the rigidity-reinforcing part 360. In the case of the sealer,the sealer is to be applied to a target part by using a sealer gun, butthere is a problem in that the sealer gun does not reach a narrow pointdescribed as in embodiments of the present invention. In addition, sincecontrol of applying a small amount of sealer is practically difficult, acertain amount of more sealer is inevitably applied. Due to thisproblem, a phenomenon occurs, where a sealer is applied to any areaother than a desired area like a pinhole, thereby causing a problem inthat the subsequent coating becomes poor in quality. In the case ofembodiments of the present invention, even when slightly excessivesealer is applied, the groove may be filled by applying the sealer firstto the recess of the rigidity-reinforcing part 360, thereby preventing adefect on a coating surface. Also, even when a pinhole is generated, thepinhole may be filled and prevented by spreading some of the filledsealer to a side. Even when the pinhole or the like is generated, thesealer may be prevented at a point where the preceding weld W1 and thefollowing weld W2 intersect each other.

Meanwhile, in the second part 300, the second junction part 320 and thecross junction part 340 are spaced apart from each other at all pointsexcept points where the second junction part 320 and the cross junctionpart 340 meet each other, and a plurality of rigidity-reinforcing parts360 and 360′ may be formed at a certain interval between the secondjunction part 320 and the cross junction part 340 spaced apart from eachother.

Particularly, a method of producing the component includes forming arigidity-reinforcing part 360 on the first part 100, the second part300, or the third part 500 adjacent to a point where the preceding weldW1 and the following weld W2 intersect each other, coupling the firstpart 100 and the second part 300 to each other by performing thepreceding weld W1 in a state of overlapping and pressurizing a part 122of the first junction part and the second junction part 320, andcoupling the first part 100, the second part 300, and the third part 500to each other by pressurizing and performing the following weld W2 whileoverlapping a part 524 of the third junction part with the opposite part124 of the first junction part and overlapping the remaining part 522 ofthe third junction part with the cross junction part 340.

First, as shown in FIG. 10 , a method performs forming therigidity-reinforcing part 360 disposed in the first part 100, the secondpart 300, or the third part 500 adjacent to the point where thepreceding weld W1 and the following weld W2 intersect each other.

In addition, as shown in FIG. 4 , the method performs coupling the firstpart 100 and the second part 300 to each other by the preceding weld W1in a state where the part 122 of the first junction part 120 and thesecond junction part 320 are overlapped and pressurized. In this step,the part 122 of the first junction part 120 and the second junction part320 are overlapped with each other, and the two junction parts aretightly fitted by pressing up and down through a jig or the like. Inthis state, laser brazing welding is performed as shown in the crosssection of FIG. 5 . Through this method, a bond is made between thetailgate outer upper panel and the extension panel. In addition, thetailgate outer upper panel and the extension panel are coupled to eachother at an angle of almost 90 degrees as shown in the drawings, therebyhaving excellent exterior design despite low formability.

In addition, as shown in FIG. 6 , the part 524 of the third junctionpart 520 is overlapped with the opposite part 124 of the first junctionpart 120, and the remaining part 522 of the third junction part 520 isoverlapped with the cross junction part 340. In this state, bypressurizing the overlapped parts and performing the following weld W2,coupling of the first part 100, the second part 300, and the third part500 is performed, and thus the assembly is completed.

FIG. 7 is a cross-sectional view taken along the line B-B of thecomponent shown in FIG. 6 . FIG. 8 is a cross-sectional view taken alongthe line C-C of the component shown in FIG. 6 . FIG. 9 is across-sectional view taken along the line D-D of the component shown inFIG. 6 .

As such, the following weld W2 is performed in the state where the part524 of the third junction part 520 and the remaining part 124 of thefirst junction part 120 are overlapped and pressurized as shown in FIG.7 . In addition, the remaining part 522 of the third junction part 520is pressurized while being overlapped with the cross junction part 340and the following weld W2 is performed as shown in FIG. 9 . Suchfollowing weld W2 occurs continuously at one time as a single process.In this case, as shown in FIG. 8 , a point where the following weld W2and the preceding weld W1 intersect each other is generated, and at thispoint, a quality problem such as having pinholes and the like may arise.

In order to solve this problem, embodiments of the present inventionform the rigidity-reinforcing part 360 in the second part 300 inadvance, as shown in FIG. 10 . The rigidity-reinforcing part 360 may bepositioned to be inclined toward the second junction part 320 from apoint between the second junction part 320 and the cross junction part340. Particularly, the rigidity-reinforcing part 360 may be in a grooveshape recessed to a certain depth to be connected to the second junctionpart 320. In addition, the sealer may be filled in the recess of therigidity-reinforcing part 360. Even when a pinhole is formed at thepoint WC where the preceding weld W1 and the following weld W2 intersecteach other, the sealer is capable of being filled in the pinhole whenthe pinhole is required to be filled up manually. In a case when thesealer is to be filled in the pinhole generated without therigidity-reinforcing part 360, the remains of the sealer may protrudeconvexly during the subsequent painting, which may cause a problem inthe coating quality.

Particularly, FIG. 6 is a view showing a state in which all componentsproduced by welding according to an exemplary embodiment of the presentinvention are coupled to each other. FIG. 1 is an enlarged view of aportion of the line A-A of the second part 300 shown in FIG. 2 . Assuch, in the first part 100 and the third part 500, both side endsthereof are welded to each other, a central part therebetween spaces thefirst part 100 and the third part 500 from each other, the second part300 is disposed at the central part, and the preceding weld W1 and thefollowing weld W2 intersect each other at an acute angle at the pointwhere the first part 100, the second part 300, and the third part 500intersect each other. As described above, in the case of a point formingthe acute angle, the welded parts are configured to be close to eachother. Thus, based on the intersecting point WC, a great deal of stressis applied to the parts. Therefore, by securing the rigidity in advancethrough the forming of the rigidity-reinforcing part 360, it is possibleto assure the quality of welding and painting.

In addition, the following weld W2 may intersect across a point spacedapart with a certain distance from the end point of the preceding weldW1. When the following weld W2 intersects at the end point of thepreceding weld W1, a lifting phenomenon may occur when coupling thethird part 500 due to the humped part of weld bead generated by thepreceding weld W1. Accordingly, this problem may be solved by allowingthe following weld W2 to intersect across a point spaced apart with acertain distance from the end point W1′ of the preceding weld W1.

According to embodiments of the present invention, the componentproduced by welding and the method of producing the same may prevent adefect of a welding area from occurring when producing by welding aplurality of panels having welding lines intersecting each other throughlaser brazing welding and the like.

Although preferred embodiments of the present invention have beendescribed for illustrative purposes, those skilled in the art willappreciate that various modifications, additions and substitutions arepossible, without departing from the technical scope and spirit of theinvention as disclosed in the accompanying claims.

What is claimed is:
 1. A method of producing a component, the methodcomprising: forming a rigidity-reinforcing part on a first part, asecond part, or a third part adjacent to a point where a preceding weldand a following weld intersect each other; coupling the first part andthe second part to each other by performing the preceding weld in astate of overlapping and pressurizing a part of a first junction partand a second junction part; and after performing the preceding weld,coupling the first part, the second part, and the third part to eachother by pressurizing and performing a following weld while overlappinga part of a third junction part with an opposite part of the firstjunction part and overlapping a remaining part of the third junctionpart with a cross junction part.
 2. The method of claim 1, whereinperforming the preceding weld comprises laser welding.
 3. The method ofclaim 1, wherein performing the following weld comprises laser welding.4. The method of claim 1, wherein performing the preceding weldcomprises laser welding and wherein performing the following weldcomprises laser welding.
 5. The method of claim 1, wherein therigidity-reinforcing part is in a groove shape recessed to a certaindepth.
 6. The method of claim 5, further comprising filling a recess ofthe rigidity-reinforcing part with a sealer.
 7. The method of claim 6,wherein the sealer is connected to a pinhole formed at the point wherethe preceding weld and the following weld intersect each other.
 8. Themethod of claim 7, wherein the pinhole is filled with the sealer.
 9. Themethod of claim 1, wherein the rigidity-reinforcing part is formed at aposition between the second junction part and the cross junction part,the position being where the second junction part and the cross junctionpart meet each other in the second part.
 10. The method of claim 1,wherein the first part, the second part, and the third part are eachmade of the same material.
 11. The method of claim 1, wherein one of thefirst part, the second part, or the third part is made of a differentmetal than others of the first part, the second part, and the thirdpart.
 12. A method of making a tailgate, the method comprising:providing a first part that comprises an upper panel of an outer panelassembly; providing a second part that comprises a lower panel of theouter panel assembly; providing a third part that comprises an extensionpanel; forming a rigidity-reinforcing part on the first part, the secondpart, or the third part adjacent to a point where a preceding weld and afollowing weld intersect each other; coupling the first part and thesecond part to each other by performing the preceding weld in a state ofoverlapping and pressurizing a part of a first junction part and asecond junction part; and after performing the preceding weld, couplingthe first part, the second part, and the third part to each other bypressurizing and performing a following weld while overlapping a part ofa third junction part with an opposite part of the first junction partand overlapping a remaining part of the third junction part with a crossjunction part.
 13. The method of claim 12, wherein performing thepreceding weld comprises laser welding and wherein performing thefollowing weld comprises laser welding.
 14. The method of claim 12,wherein the rigidity-reinforcing part is in a groove shape recessed to acertain depth, further comprising filling a recess of therigidity-reinforcing part with a sealer.
 15. The method of claim 14,wherein the sealer is connected to a pinhole formed at the point wherethe preceding weld and the following weld intersect each other, whereinthe pinhole is filled with the sealer.
 16. The method of claim 12,wherein the first part, the second part, and the third part are eachmade of the same material.
 17. The method of claim 12, wherein one ofthe first part, the second part, or the third part is made of adifferent metal than others of the first part, the second part, and thethird part.